Linear Polar - Nonpolar Diblock Copolymers and Use Thereof

Abstract

A linear diblock copolymer of the general structure “Polymer A-linkage-Polymer B”, wherein Polymer A is essentially a nonpolar polymeric entity being a copolymer of propylene and ethylene, with propylene representing 51 to 99 weight percent of Polymer A; and Polymer B is a polymeric polar entity; and the use of said diblock copolymer to modify polymer bulk and interfacial properties in end applications as well as the intermediate material Polymer A-linkage useful in the manufacture of the diblock copolymer.

1 : A diblock copolymer of the following structure: 
       
         
           
           
               
               
           
         
         where R and R 1  may be the same or different and each independently represents an alkyl or aryl group, X may be hydrogen or a C1 to C20 alkyl group which may be branched or linear and wherein the aromatic ring substituent joined to Polymer B is positioned meta or para to the aromatic ring substituent joined to Polymer A, characterized in that: 
         a) Polymer A is a polymer which consists essentially of recurring units derived from propylene and ethylene, wherein the propylene content is from 51 to 99 percent based on total number average molecular weight of Polymer A with the balance to 100 percent being derived from ethylene; and 
         b) Polymer B is a chain of structural units derived from one or more α,β-unsaturated monomers selected from the group consisting of styrene, substituted styrene, acrylate, methacrylate, vinyl esters, fumarate esters and maleic anhydride and derivatives thereof, and diene compounds. 
       
     
     
         2 : The diblock copolymer of  claim 1 , wherein the propylene-ethylene-derived copolymer (Polymer A) has a propylene content of from 55 to 95 percent. 
     
     
         3 : The diblock copolymer of  claim 1 , wherein Polymer B is a chain of structural units derived from acrylate, methacrylate, vinyl esters, fumarate esters and maleic anhydride and derivatives thereof, or combinations of two or more thereof. 
     
     
         4 : A polymer composition comprising the diblock copolymer as claimed in  claim 1 . 
     
     
         5 : An article comprising:
 a substrate having an outer surface; and   a layer of a polymer composition contiguous to said outer surface of the substrate, wherein the polymer composition comprises the diblock copolymer as claimed in  claim 1 .   
     
     
         6 : Use as an additive to a polymer composition of the diblock copolymer as claimed in  claim 1 , wherein the additive is present in an amount of from about 0.1 to about 20 weight percent based on total weight of the polymer composition including additive. 
     
     
         7 : A method of preparing the diblock copolymer of  claim 1 , comprising:
 a) in a first step, polymerizing propylene and ethylene in the presence of a metallocene catalyst to form Polymer A, wherein the propylene content is from about 51 to about 99 percent based on total number average molecular weight of Polymer A with the balance to 100 percent being derived from ethylene, the reaction being carried out in the presence of a linkage molecule of Formula II:   
       
         
           
           
               
               
           
         
         in a reaction vessel, wherein, in the course of the reaction, the linkage molecule is terminally incorporated onto Polymer A resulting in the formation of a terminally unsaturated intermediate of Formula III: 
       
       
         
           
           
               
               
           
         
         b) in an optional second step, recovering the intermediate III from the reaction mixture of the first step; and 
         c) in a third step, reacting the intermediate III at its terminal double bond with a polar monomer in a subsequent polymerization reaction to form Polymer B, where R, R1 and X are as previously defined. 
       
     
     
         8 : A method of manufacturing the diblock copolymer of  claim 1 , comprising providing and charging to a reaction vessel a terminally unsaturated polymeric material corresponding to Formula III, further introducing to the reaction vessel one or more α,β-unsaturated monomers selected from the group consisting of styrene, substituted styrene, acrylate, methacrylate, vinyl esters, fumarate esters and maleic anhydride and derivatives thereof, and diene compounds, and causing said α,β-unsaturated monomers to react at its terminal unsaturation in a subsequent polymerization reaction to form and adjoin Polymer B, where R, R1 and X are as previously defined. 
     
     
         9 : Use as an additive to polymer materials of a diblock copolymer of the following structure: 
       
         
           
           
               
               
           
         
         where R and R1 may be the same or different and each independently represents an alkyl or aryl group, X may be hydrogen or a C1 to C20 alkyl group which may be branched or linear and wherein the aromatic ring substituent joined to Polymer B is positioned meta or para to the aromatic ring substituent joined to Polymer A, wherein Polymer A is a non-polar polymer formed by metallocene catalyzed polymerization of propylene with ethylene, wherein the propylene content is from about 51 to about 99 percent based on total number average molecular weight of Polymer A with the balance to 100 percent being derived from ethylene; and Polymer B is a polymer formed by radical catalysis of a polar monomer. 
       
     
     
         10 : A polymer of the following Formula III: 
       
         
           
           
               
               
           
         
         where R and R 1  may be the same or different and each independently represents an alkyl or aryl group, X may be hydrogen or a C1 to C20 alkyl group which may be branched or linear and wherein the aromatic ring substituent corresponds to a meta- or para-configuration, and further wherein Polymer A consists essentially of recurring units derived from propylene and ethylene, wherein the propylene content is from about 51 to about 99 percent based on total number average molecular weight of Polymer A with the balance to 100 percent being derived from ethylene. 
       
     
     
         11 : The polymer according to  claim 10 , wherein the polymer is used for preparing a diblock copolymer of the following structure: